Electric vehicles with range extenders and related methods

Abstract

A hybrid vehicle includes an electric motor coupled to and configured to drive one or more wheels of the vehicle, a floor pan, a high-voltage battery, a range extender, and a fuel tank. The high-voltage battery is configured to supply power to the electric motor. The high-voltage battery is positioned beneath the floor pan. The range extender includes an internal combustion engine and a generator coupled to the internal combustion engine. The generator is configured to supply power to charge the high-voltage battery. The fuel tank is configured to store fuel for the internal combustion engine. The fuel tank is positioned beneath the floor pan adjacent the high-voltage battery and has a height that is substantially the same as a height of the high-voltage battery.

Description

ELECTRIC VEHICLES WITH RANGE EXTENDERS AND RELATED METHODSFIELD OF INVENTION

[0001] The present invention relates generally to arranging a range extender and other vehicle components with spatial efficiency.BACKGROUND

[0002] Hybrid vehicles combine an internal combustion engine (ICE) with an electric motor that is powered by a battery. The combination of the ICE and electric motor allow the hybrid vehicles to utilize both gasoline via the ICE and electricity via the electric motor for driving. In some cases, hybrid vehicles may include a range extender (REX) that allows the hybrid vehicles to travel further than an initial or previous driving range for the hybrid vehicles. In particular, a REX includes an ICE that generates electricity to power the electric motor of the vehicle. When the battery of the hybrid vehicles is fully charged, the electric motor powers the hybrid vehicles and the REX remains idle or unused. As the battery of the hybrid vehicles charge drops, the REX may be activated to provide power to the electric motor.

[0003] The dimensions and / or the size of the space often used for the components in hybrid vehicles has remained compact and approximately the same overtime while the quantity and / or the size of components has increased, resulting in spatial challenges. Arrangement of the components in a space often used for the particular components may also result in spatial challenges. In addition to spatial challenges, operational challenges may occur when placing the particular components in a new space of the hybrid vehicles (e.g., at the rear of the hybrid vehicles rather than at the front, or vice versa).SUMMARY

[0004] Embodiments of the present vehicles address spatial and operational challenges in electric vehicles, such as a hybrid vehicle. The spatial and operational challenges are addressed by disposing an internal combustion engine (ICE) motor of a range extender (REX) in a cavity (e.g., a space) resulting from reducing a battery size of the hybrid vehicle and / or space that is unused or available below rear seats of the vehicles. In some examples, the cavity may be formed along or defined by a floor pan of the hybrid vehicle. The spatial and operational challenges may also be addressed by a power module that includes the REX and the fuel tank as a single package or module and that is configured to fit into the cavity. The power module may be directly plugged into the battery of the hybrid vehicle and / or may be mounted and integrated with other components in the cavity.

[0005] In some examples, the REX may be disposed on a battery housing of the battery of the hybrid vehicle, in the cavity. In addition to the REX (e.g., including the ICE and in some examples, the generator), an inverter, an exhaust aftertreatment system, an intake system, a fuel tank, and hardware wiring for interconnecting the components within or external to the REX, may be disposed in the cavity.

[0006] In particular, the ICE and / or the generator of the REX may be disposed in the cavity that is formed based on the reduced battery size of the hybrid vehicle and the space underneath the rear seat of the hybrid vehicle. As an example, the cavity may have a length of at least 500 millimeter (mm) (e.g., 550 mm) and a height of at least 280 mm (e.g., 300 mm). In some examples, another portion of the cavity may have a length of at least 70 mm and have a height of at least 300 mm.

[0007] In some examples, the REX may include an ICE that allows for increased power density and has a compact size. The REX may combine the efficiency and low emissions of a 4-stroke engine in a 1 -stroke or 2-stroke ICE. Such examples of the REX may be provided or manufactured by INNengine. The ICE of such REXs may utilize an opposed-piston design, have fewer components, have a high power-to-weight ratio, and have improved efficiency and lower emissions (e.g., based on a combustion cycle and compact design that improves thermal efficiency and results in reduced fuel consumption and emissions).

[0008] These approaches of disposing the ICE and / or the generator of the REX in a cavity defined by the floor pan that is available by reducing the battery size in the vehicle and / or by using space available under the rear seats, facilitates spatially efficient utilization of space to allow additional and / or larger components in a hybrid vehicle as technology advances for hybrid vehicles. The spatially efficient utilization of space may also occur without increasing the size of the vehicle and without compromising operations associated with the components. For example, the components may continue operating or performing as expected. Also, the cavity may be formed under the rear seats to facilitate an all-wheel drive (AWD) drivetrain system in the hybrid vehicle. The AWD may involve, for example, three motors — two that are each associated with a respective one of the rear wheels and one, connected to a differential, associated with the front wheels. For example, the rear subframe and the front subframe of the hybrid vehicle may each include two motors to rotate two respective wheels or one motor to rotate the front wheels or the rear wheels, respectively, of the vehicle. Motor(s) may be not fit at the front subframe along with a REX. Accordingly, by having the cavity for the REX defined with respect to the rear seats, the hybrid vehicle may still use AWD while also gaining the benefit of increased driving range provided by the REX.

[0009] The term “coupled” is defined as connected, although not necessarily directly, and not necessarily mechanically; two items that are “coupled” may be unitary with each other. The terms “a” and “an” are defined as one or more unless this disclosure explicitly requires otherwise. The terms “substantially,” “about,” and “approximately” are each defined as largely but not necessarily wholly what is specified — and include what is specified, e.g., substantially 90 degrees includes 90 degrees and substantially parallel includes parallel — as understood by a person of ordinary skill in the art. As used herein, “substantially parallel” means within 10 degrees of parallel to, and “substantially perpendicular” means within 10 degrees of perpendicular to. In any disclosed embodiment, the terms “approximately” and “about” may each be substituted with “within [a percentage] of’ what is specified, where the percentage includes 0.1, 1, 5, and 10 percent.

[0010] The terms “comprise” and any form thereof such as “comprises” and “comprising,” “have” and any form thereof such as “has” and “having,” and “include” and any form thereof such as “includes” and “including” are open-ended linking verbs. As a result, an apparatus or system that “comprises,” “has,” or “includes” one or more elements possesses those one or more elements but is not limited to possessing only those elements. Likewise, a method that “comprises,” “has,” or “includes” one or more steps possesses those one or more steps but is not limited to possessing only those one or more steps.

[0011] Any embodiment of any of the apparatuses, systems, and methods can consist of or consist essentially of — rather than comprise / have / include — any of the described steps, elements, and / or features. Thus, in any of the claims, the term “consisting of’ or “consisting essentially of’ can be substituted for any of the open-ended linking verbs recited above in order to change the scope of a given claim from what it would otherwise be using the open-ended linking verb.

[0012] Further, an apparatus or system that is configured in a certain way is configured in at least that way, but it can also be configured in other ways than those specifically described.

[0013] The feature or features of one embodiment may be applied to other embodiments, even though not described or illustrated, unless expressly prohibited by this disclosure or the nature of the embodiments.

[0014] Some details associated with the embodiments described above and others are described below.BRIEF DESCRIPTION OF THE DRAWINGS

[0015] The following drawings illustrate by way of example and not limitation. For the sake of brevity and clarity, every feature of a given structure is not always labeled in everyfigure in which that structure appears. Identical reference numbers do not necessarily indicate an identical structure. Rather, the same reference number may be used to indicate a similar feature or a feature with similar functionality, as may non-identical reference numbers.

[0016] FIG. 1 is a block diagram of an example of one of the electric vehicles that includes a range extender in a rear cavity of the vehicle.

[0017] FIG. 2 is a cross-sectional view of the vehicle of FIG. 1 and illustrates the cavity. The vehicle’s unibody in FIG. 2 is drawn to scale.

[0018] FIG. 3A is an example of an arrangement of components with the range extender in the cavity of FIG. 1.

[0019] FIG. 3B is an example of an arrangement of components with the range extender in the cavity of FIG. 1.

[0020] FIG. 3C is an example of an arrangement of components with the range extender in the cavity of FIG. 1.

[0021] FIG. 4A is an example of an internal combustion engine of the range extender of FIG. 1.

[0022] FIG. 4B is schematic view of the internal combustion engine of FIG. 4A.

[0023] FIG. 5 is an example of a power module including the range extender of FIG. 1.DETAILED DESCRIPTION

[0024] Some electric vehicles may include a range extender (REX) that allows electric vehicles, such as hybrid vehicles, to travel further than a typical driving range for the electric vehicles. In particular, a REX may include an internal combustion engine (ICE) that generates electricity to power an electric motor of a hybrid vehicle when the charge of the battery falls below a threshold charge (e.g., charge is below a threshold of 10% of the capacity charge).

[0025] The dimensions and / or the size of the space often used for components in hybrid vehicles has remained approximately the same overtime while the quantity and / or the size of components has increased, resulting in spatial challenges. Arrangement of the components or how the components are disposed with respect to each other in the space, may also result in spatial challenges, as well as operational challenges.

[0026] The techniques discussed herein address spatial and operational challenges by disposing an ICE and / or a generator of a REX in a cavity (e.g., a space) of a hybrid vehicle (e.g., one or more hybrid vehicles). The cavity may be defined by the floor pan of the hybrid vehicle and may result from reduced battery size and / or space available below rear seats of the hybrid vehicle. In some examples, the REX may be disposed on battery housing in the cavity. In addition to the REX (e.g., ICE and / or generator of the REX), an inverter, an exhaustaftertreatment system, an intake system, a fuel tank, and / or hardware wiring for interconnecting the components within or external to the REX, may be disposed in the cavity.

[0027] For example, reducing the battery size in the electric vehicle may result in space that may be utilized for the REX. The ICE and / or the generator of the REX may be disposed in the space resulting from the reduced battery size. The space underneath the rear seats of the vehicle may also include space, which may unused, and that may additionally or alternatively be used for the ICE and / or the generator of the REX. Accordingly, the ICE and / or the generator of the REX may be disposed in the cavity including space resulting from both the reduced battery size and the space below the rear seats. As an example, the cavity may include a space that has a length that may be greater than or equal to any one of, or between any two of: 300, 350, 400, 450, 500, 550, and 600 millimeter (mm) (e.g., length of 550 mm). The space may have a height that may be greater than or equal to any one of, or between any two of: 100, 200, 300 mm (e.g., height of 300 mm). In some examples, additional space that is adjacent to the space (e.g., that has a length of 550 mm) may be used, and the additional space may have a length that is greater than or equal to any one of, or between any two of: 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, and 100 mm (e.g., length of 70 mm). The additional space may have a height that may be greater than or equal to any one of, or between any two of: 100, 200, 300 mm (e.g., height of 300 mm).

[0028] In some examples, the REX may combine the efficiency and low emissions of a 4-stroke engine in a simple 1 -stroke or 2-stroke ICE. Such examples of the REX may be provided or manufactured by INNengine. For example, all four stages of the combustion cycle — intake, compression, power, and exhaust — may be effectively performed in a single cycle, resulting in simpler and more efficient operation of the ICE. As an example, the ICE may utilize an opposed-piston design, have fewer components, have a high power-to-weight ratio, and have improved efficiency and lower emissions (e.g., based on the combustion cycle and compact design that improves thermal efficiency and results in reduced fuel consumption and emissions). Accordingly, such a REX may increase the driving range without significantly increasing emissions or fuel consumption by the hybrid vehicle.

[0029] The techniques discussed herein of the REX in a cavity defined by the floor pan that is available by reducing the battery size in the hybrid vehicle and / or by using space available under the rear seats, facilitates spatially efficient utilization of space. Such efficient utilization of space may allow additional and / or larger components in the hybrid vehicle as technology advances for hybrid vehicle. For example, the efficient utilization of space may occur without increasing the size of the vehicle and without compromising operation of the components ofthe hybrid vehicle (e.g., components may continue operating or performing as expected). Also, the cavity may be formed under the rear seats rather than the front seats to facilitate an allwheel drive (AWD) as a drivetrain system in the electric vehicle. The AWD may involve three motors, with two that are each associated with a respective rear wheel, and one, connected to a differential, that is associated with the front wheels. For example, a rear subframe and a front subframe of the electric vehicle may each include one or two motors to rotate the rear and front, respectively, wheels. Motor(s) may not fit at the front subframe along with a REX. Accordingly, by having the cavity for the REX defined along the rear seats, the hybrid vehicle may still use AWD while also benefiting from range enhancements provided by the REX.

[0030] FIG. 1 is a block diagram of an example of one of the electric vehicles 100 that includes a REX in a rear cavity of the vehicle 100 in accordance with one or more aspects of the present disclosure. In some examples, the vehicle 100 may be a hybrid vehicle. The vehicle 100 may include a REX in the cavity resulting from a reduced battery size and / or under the rear seats, as discussed in detail with respect to FIG. 2.

[0031] The block diagram provides a visual representation of some of the components of the vehicle 100, for example, that may be associated with or relate to efficiently positioning the REX 110 in the rear cavity of the vehicle 100. As an example, the vehicle 100 may include, among other devices and components, an electric motor 102, a high-voltage (HV) battery 104, a fuel tank 106, a floor pan 108, a REX 110, and wheels 116. The REX 110 may include an ICE 112 and / or a generator 114.

[0032] The electric motor 102 may convert electrical energy stored in a battery, such as the HV battery 104, into mechanical energy. The mechanical energy may drive the wheels 116 relative to the body of the vehicle 100 to move the vehicle 100, for example, allowing the vehicle to accelerate, decelerate, and / or maintain speed.

[0033] The HV battery 104 may be greater than a 100V battery (e.g., often between 200V and 800V). The HV battery 104 may be the energy source for powering the electric motor 102. For example, the HV battery 104 may provide the electrical energy that is used to drive the vehicle 100 (e.g., by the electric motor 102 converting this energy into mechanical energy to drive the wheels 116). In some examples, the HV battery 104 may have a capacity for storing energy, and the energy may impact a driving range of the vehicle 100. Generally, the size of the battery may correspond to the range. For example, large HV batteries 104 may store more energy than a relatively smaller HV batteries, and the energy may correspond to driving range. Accordingly, a large HV battery 104 may provide a greater range of driving for the vehicle 100 than a small HV battery 104.

[0034] As discussed herein, the size of the HV battery 104 may be reduced, making space available in the cavity below the floor pan 108, as discussed in detail with respect to FIG. 2. However, the REX may compensate for the loss in driving range resulting from the reduced battery size.

[0035] The floor pan 108 of the vehicle 100 may be a structural platform that forms the base of the chassis of the vehicle 100 and may also house the HV battery 104. The HV battery 104 may be set in a flat, protective compartment beneath the cabin of the vehicle 100 (e.g., under the floor pan 108). Thus, by reducing the size of the HV battery 104, space may become available at the base of the chassis of the vehicle 100 (e.g., under the floor pan 108).

[0036] As discussed herein, the REX 110 may facilitate in powering the electric motor 102 (e.g., when the HV battery 104 has a charge below a threshold state of charge). The REX 110 may include an ICE 112 and a generator 114. As discussed further and illustrated in FIG. 2, the REX 110 may be positioned beneath the floor pan 108, such that the ICE 112 is disposed within the cavity (e.g., resulting from at least the reduced HV battery 104 size) and between a front wheel center associated with front wheels 116 of the vehicle 100 and a rear wheel center associated with rear wheels 116 of the vehicle 100.

[0037] The ICE 112 of the REX 110 may be a backup power source to generate electricity when the charge of the HV battery 104 falls below a threshold battery charge, for example, to extend the driving range of the vehicle 100 when using the HV battery 104. The ICE 112 may operate a generator 114 to supply additional power to recharge the HV battery 104 to allow the vehicle 100 to continue driving (e.g., with the HV battery 104 having a low charge). The ICE 112 may also provide power when the vehicle 100 is operating such that more power may be used, for example, when the vehicle 100 is accelerating or driving on an atypical terrain.

[0038] The generator 114 of the REX 110 may convert mechanical energy from the ICE 112 into electrical energy. When the charge of the HV battery 104 is below a threshold charge, the electrical energy from the generator 114 may be used to recharge the HV battery 104 and / or supply the electric motor 102 directly so that the vehicle 100 may continue driving.

[0039] The fuel tank 106 may store gasoline or another liquid or gaseous fuel, which is used to power the ICE 112 of the REX 110. The vehicle 100 (e.g., hybrid vehicle) may combine the ICE 112 with the electric motor 102 and an HV battery 104, to use fuel and / or electricity as energy sources for driving. The fuel tank 106 may allow a hybrid vehicle to operate over longer distances with respect to purely electric vehicles since the hybrid vehicle can switch to gasoline when the HV battery 104 is below the threshold charge.

[0040] As discussed further and illustrated in FIG. 2, the fuel tank 106 may be positioned beneath the floor pan 108 adjacent the HV battery 104. In some examples, other components 118, such as an inverter, an exhaust-aftertreatment system, an intake system, and hardware wiring, may be disposed in the cavity along with the ICE 112 and / or the generator 114 of the REX 110. Accordingly, the cavity may be formed beneath the floor pan 108 and the rear seats, and may include the REX 110, the fuel tank 106, the inverter, the exhaust-aftertreatment system, the intake system, and the hardware wiring.

[0041] FIG. 2 is a cross-sectional view 200 of the vehicle 10 of FIG. 1 and illustrates the cavity in accordance with one or more aspects of the present disclosure. As illustrated, the vehicle 10 includes the fuel tank 106, floor pan 108, the REX 110 (e.g., including the ICE and / or the generator) the HV battery 104, and wheels 116 that may operate or function as discussed with respect to FIG. 1. For example, the HV battery 104 may be configured to supply power to an electric motor of the vehicle 10, the electric motor may be coupled to and configured to drive one or more wheels 116 of the vehicle 10, the generator of the REX 110 may be coupled to the ICE of the REX 110 and configured to supply power to charge the HV battery 104, and the fuel tank 106 may be configured to store fuel for the ICE of the REX 110.

[0042] As illustrated by the dashed line box, the floor pan 108 defines a cavity 202 and the HV battery 104, the fuel tank 106, and the REX 110 may be disposed in the cavity 202. In some examples, such components and others as discussed with respect to FIG. 1 and FIG. 5, may be packaged into a single power module 250 for efficient placement within the cavity 202 (e.g., where the package dimensions are based on the cavity 202 dimensions). In some examples, the HV battery 104 may be positioned beneath the floor pan 108 and the fuel tank 106 may be positioned beneath the floor pan 108 adjacent the HV battery 104 in the cavity 202. The fuel tank 106 may have a height that is substantially the same as a height of the HV battery 104. The REX 110 may be positioned beneath the floor pan 108 such that the ICE of the REX 110 may be disposed within the cavity 202 between a front wheel center associated with the front wheels 116-a of the vehicle 10 and a rear wheel center associated with the rear wheels 116-b of the vehicle 10.

[0043] The cavity 202 may have a length that may be greater than or equal to any one of, or between any two of: 300, 350, 400, 450, 500, 550, and 600 mm (e.g., length of 550 mm), and a height that may be greater than or equal to any one of, or between any two of: 100, 200, 300 mm (e.g., height of 280 mm or 300 mm). A portion of the length that may be greater than or equal to any one of, or between any two of: 300, 350, 400, 450, 500, 550, and 600 mm (e.g., length of 550 mm) and a second portion of the length that is greater than or equal to any oneof, or between any two of: 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, and 100 mm (e.g., length of 70 mm; 620 mm total length).

[0044] As an example, the cavity 202 may have a length of at least 500 mm (e.g., 550 mm) and a height of at least 280 mm (e.g., 300 mm). A portion of the length may be at least 500 mm (e.g., 550 mm) and a second portion of the length may be 70 mm (e.g., 620 mm total length). The cavity 202 may be defined beneath the floor pan 108 in an area allocated for rear seats 204 of the vehicle 10. Accordingly, the cavity 202 may be further defined by the rear seats 204 (e.g., the portion of the floor pan 108 that is allocated for rear seats 204). The cavity 202 may be positioned forward (e.g., facing towards the front of the vehicle 10) of a rear wheel 116-b of the vehicle 10, such that at least a portion of the cavity 202 is positioned beneath a rear seat 204 of the vehicle 10. As discussed in detail with respect to FIG. 5, a power module 250 may be disposed inside of the cavity 202 and that, for example, includes the HV battery 104 and the REX 110.

[0045] In some examples, a fuel pump associated with the fuel tank 106 may be configured to supply fuel to the ICE of the REX 110 that is disposed within the cavity 202. The generator may be disposed within the cavity 202. In some examples, the ICE may include annularly disposed combustion chambers, and for each of the combustion chambers, opposing pistons reciprocatably may be disposed therein, as discussed with respect to FIG. 3A. In some examples, the ICE may be a flat engine or a boxer engine, as discussed with respect to FIG.3B. In other examples, the ICE may be a turbine engine, as discussed with respect to FIG. 3C.

[0046] In some examples, the vehicle 10 may include a supercharger that is configured to supply compressed air to the ICE of the REX 110. The supercharger may increase the power output of the ICE by forcing more air into the intake of the ICE, facilitating in burning more fuel and producing more power. In some examples, the supercharger may pull air from outside the vehicle 10, compressing it the air before it enters the ICE’s intake. By increasing the density of the air, more oxygen may fit into the combustion chamber of the ICE. In some examples, the supercharger may be an electric supercharger. The generator of the REX 110 may include an electric motor configured to start the ICE. Additionally, or alternatively, the supercharger may facilitate exhaust gas scavenging.

[0047] In some examples, a method of manufacturing the vehicle 10 (e.g., with the cavity 202 described herein), may include coupling a first HV battery 104 to a floor pan 108 of a first vehicle 10 defining a space for the first HV battery 104. The method may include coupling a second HV battery 104 to a floor pan 108 of a second vehicle 10.

[0048] The floor plan of the second vehicle 10 may be the same as the floor pan 108 of the first vehicle 10. The second HV battery 104 may have a length that may be greater than or equal to any one of, or between any two of: 1%, 5%, 7%, 10%, 15%, less than a length of the first HV battery 104 (e.g., second HV battery 104 has a length that is 5% less than the length of the first HV battery 104). The method may include coupling a fuel tank 106 to the floor pan 108 of the second vehicle 10 such that the fuel tank 106 may be at least partially disposed in the space for the first HV battery 104.

[0049] In some examples, the fuel tank 106 may have a height that may be substantially the same as a height of the first HV battery 104. The floor pan 108 of the second vehicle 10 may define a cavity 202. In such examples, the method may further include coupling a REX 110 to the second vehicle 10, where the range extender 110 includes an ICE and a generator coupled to the ICE. The generator may be configured to supply power to the second HV battery 104. The coupling of the REX 110 to the second vehicle 10 may be performed such that the ICE may be disposed within the cavity 202 and between a front wheel center associated with the front wheel 116-a of the second vehicle 10 and a rear wheel center associated with the rear wheel 116-b of the second vehicle 10. In some examples, a fuel pump configured to supply fuel to the ICE may be disposed within the cavity 202, and the generator may also be disposed within the cavity 202.

[0050] The techniques discussed herein may be implemented with different ICE technology including different types of reciprocating piston engines, microturbine generators, etc. For example, FIG. 3A is an example of an arrangement of components 300-a with the REX in the cavity of FIG. 2, in accordance with one or more aspects of the present disclosure. In this example, the ICE may be a cylindrical reciprocating piston ICE. The arrangement of components 300-a may include an HV battery 104, a fuel tank 106, and cylindrical reciprocating piston ICE 112-a, that may operate or function as discussed with respect to FIG.1. The arrangement of components 300-a may also include an air filter 302, a REX engine control unit 304 (ECU), an electric motor (e.g., electric motor 102) and inverter 306, cooling hoses 308, an exhaust, silencer, and aftertreatment system 310, an insulation firewall 312, and a range extender subframe 314. The components in the arrangement of components 300-a may fit within and be disposed in the cavity 202, as discussed with respect to FIG. 2. In some examples, the components in the arrangement of components 300-a may be packaged as the power module 250, as discussed with respect to FIG. 5.

[0051] The cylindrical reciprocating piston ICE 112-a is a type of engine where power may be generated by igniting fuel via a cylinder. Fuel may be provided to the cylinder and ignited(e.g., via a spark plug or the like), generating high-pressure gases that push the piston down and cause it to move in a reciprocating motion. The reciprocating motion may be converted into a rotational motion to power components of the vehicle. In particular, a rod connects the piston to a crankshaft, which converts the linear motion (e.g., up-and-down motion) of the pistons into rotational motion, for example, to drive the wheels of the vehicle.

[0052] The air filter 302 may be an air filter that traps airborne contaminant particles, such as dust, pollen, road debris, and the like. The arrangement of components 300-a may also include a supercharger, which compresses incoming air to increase the oxygen available for combustion, boosting power output at the ICE 112-a. The air filter 302 may ensure that the contaminant particles do not reach the supercharger or the ICE 112-a that would otherwise cause damage, reducing lifespan of the supercharger and / or the ICE 112-a.

[0053] The REX ECU 304 may be a control unit that manages the REX that includes the cylindrical reciprocating piston ICE 112-a. For example, the REX ECU 304 may monitor the state of charge of the HV battery 104 and remaining driving range. When the charge falls below a threshold charge, the REX ECU 304 may activate the REX to maintain vehicle operation and extend the range. Once the REX is active, the REX ECU may also manage the ICE 112-a and / or generator of the REX. The REX ECU 304 may also manage and allocate how much power from the REX is allocated to the HV battery 104 and the electric motor (e.g., the electric motor and inverter 306).

[0054] The electric motor of the electric motor and inverter 306, may operate as discussed with respect FIG. 2. The inverter of the electric motor of the electric motor and inverter 306 may convert a direct current (DC) supply from the HV battery 104 into an alternating current (AC) output. The AC output may power the electric motor that drives the vehicle. The cooling hoses 308 may regulate the temperature of the components in the arrangement of components 300-a, for example, the HV battery 104, electric motor, etc. Regulating the temperature may include the cooling hoses 308 directing coolant (e.g., from a liquid cooling system) to the arrangement of components 300-a.

[0055] The exhaust of the exhaust, silencer, and aftertreatment system 310 may channel exhaust gases from the ICE 112-a (e.g., through a tailpipe) to outside of the vehicle while also reducing emissions and noise. A silencer (e.g., muffler) of the exhaust, silencer, and aftertreatment system 310 may reduce noise. The aftertreatment system of the exhaust, silencer, and aftertreatment system 310 may include a catalytic converter that actively cleans the exhaust gases by converting harmful pollutants into less harmful emissions.

[0056] The insulation firewall 312 may be a barrier between the passenger cabin of the vehicle and the ICE 112-a of the vehicle. The insulation firewall 312 may provide thermal insulation (e.g., reduce heat) and reduce sound. The insulation firewall 312 may be made of a combination of materials such as foil heat shields, melamine foam, organic fibers, and the like. In some examples, a fuel inlet port of the fuel tank 106 may include a filler pipe that guides fuel from a fuel filler port to the fuel tank 106. The fuel inlet port may be entry point where fuel enters the combustion chamber of the ICE 112-a directly or into an intake manifold before the inlet port.

[0057] The REX subframe 314 may be a structural component, such as a frame, that supports the components of the REX relative to the vehicle. The REX subframe 314 may be used as a mounting platform for the REX (e.g., the ICE 112-a and / or the generator), as well as the exhaust, silencer, and aftertreatment system 310, cooling hoses 308, etc. The frame may be made of lightweight aluminum to accommodate a variety of structures (e.g., linear, curved, etc.) and may provide stability and alignment during vehicle operation. In some examples, the subframe width may be at approximately 250 mm or a width that allows securely fitting the ICE 112-a to provide stability during driving. The insulation firewall 312 may be at least 540 mm in some examples.

[0058] FIG. 3B is an example of an arrangement of components 300-b with the REX in the cavity of FIG. 2, in accordance with one or more aspects of the present disclosure. In this example, the ICE 112 may be a flat or boxer reciprocating piston ICE 112-b. The arrangement of components 300-b may include an HV battery 104, a fuel tank 106, an air filter 302, a REX ECU 304, an electric motor (e.g., electric motor 102 of FIG. 1) and inverter 306, cooling hoses 308, an exhaust, silencer, and aftertreatment system 310, an insulation firewall 312, and a REX subframe 314, that may operate or function as discussed with respect to FIG. 3 A. The arrangement of components 300-b may include a flat or boxer reciprocating piston ICE 112-b, that may operate or function as discussed with respect to the ICE 112 of FIG. 1. The components in the arrangement of components 300-b may fit within and be disposed in the cavity 202, as discussed with respect to FIG. 2. In some examples, the components in the arrangement of components 300-b may be packaged as the power module 250, as discussed with respect to FIG. 5.

[0059] The flat or boxer reciprocating piston ICE 112-b is a type of ICE 112 with horizontally aligned cylinders and pistons that move in and out in pairs (e.g., inward and outward motions at the same time), in a “boxer” or “boxing” configuration. The cylinders may be arranged in two banks on opposite sides of a crankshaft, forming a flat, wide configuration.For example, each piston in a respective bank may have a corresponding piston in the opposite bank that moves in the opposite direction in the “boxer” motion. Such engines (e.g., ICE 112-b) may be associated with low vibration and may be balanced, providing a high performance and power without vibration. Flat engines may also have a low center of gravity that may improve driving performance of the vehicle.

[0060] FIG. 3C is an example of an arrangement of components 300-c with REX in the cavity of FIG. 2, in accordance with one or more aspects of the present disclosure. In this example, the ICE 112 may be a microturbine generator ICE 112-c. The arrangement of components 300-c may include an HV battery 104, a fuel tank 106, an air filter 302, a REX ECU 304, an electric motor (e.g., electric motor 102 of FIG. 1) and inverter 306, cooling hoses 308, an exhaust, silencer, and aftertreatment system 310, an insulation firewall 312, and a REX subframe 314, that may operate or function as discussed with respect to FIG. 3 A. The arrangement of components 300-c may include a microturbine generator ICE 112-c, that may operate or function as discussed with respect to the ICE 112 of FIG. 1. The components in the arrangement of components 300-c may fit within and be disposed in the cavity 202, as discussed with respect to FIG. 2. In some examples, the components in the arrangement of components 300-c may be packaged as the power module 250, as discussed with respect to FIG. 5.

[0061] The arrangement of components 300-c may also include acoustic insulation 330 and a high-speed connecting shaft 334. The acoustic insulation 330 may be material or the link that reduces sound and vibration in the cabin of the vehicle. The acoustic insulation 330 may be materials, such as acoustic foams, damping pads, sound-deadening mats, and the like.

[0062] The microturbine generator ICE 112-c may be a small gas turbine that may generate both electricity and heat and it may provide an electrical output that is greater than or equal to any one of, or between any two of: 20, 25, 40, 50, 100, 150, 250, and 300 kilowatts (kW) (e.g., between 25 kW and 250 kW). The microturbine generator ICE 112-c may be an ICE 112 that uses a gas turbine driven by combusted fuel to generate the electricity. In some examples, microturbine generator ICE 112-c may use a rotating turbine to convert the energy from combustion into electrical power using a generator that is connected to the turbine. In the generator, the rotational energy of the turbine may drive the rotor to induce an electrical current in the stator, producing electricity.

[0063] The high-speed connecting shaft 334 may be a shaft that rotates the turbine, compressor, and generator of the microturbine generator ICE 112-c. For example, the highspeed connecting shaft 334 may connect the turbine rotor to the generator rotor. Themicroturbine generator ICE 112-c may burn fuel to generate high-pressure gases, which spin the turbine. Since the high-speed connecting shaft 334 is connected to the turbine rotor, it transmits the rotational energy produced by the turbine to the generator. Accordingly, the generator rotor may be powered by the high-speed connecting shaft 334, which induces an electrical current in the stator of the generator, producing electricity. Accordingly, the highspeed connecting shaft 334 may function as a mechanical link between the energy produced by the combustion process of the microturbine generator ICE 112-c and the electrical output of the generator of the microturbine generator ICE 112-c. The microturbine generator ICE 112-c may provide a small sized and efficient power generation that may be useful based on the cavity dimensions and based on the arrangement of components 300-c.

[0064] FIG. 4A is an example of an ICE 112 of a REX of FIG. 1, in accordance with one or more aspects of the present disclosure. The ICE 112 may include a main shaft 404, a cam-track 406, one a piston group 408, a shifting device 410, and an engine block 414. As discussed herein, the ICE 112 may utilize a 1-stroke or 2-stroke engine technology. For example, the ICE 112 that utilizes a 1-stroke or a 2-stroke technology may combine all four stages of the combustion cycle — intake, compression, power, and exhaust — into the 1 or 2 cycles. An ICE with that combines the multiple stages into fewer stages may provide a relatively simpler and more efficient operation with respect to a 4-stroke engine. As an example, INNengine may supply the ICE 112 having the 1-stroke or the 2-stroke engine.

[0065] The depicted ICE 112 may be a 2-stroke engine. The piston group 408 may operate similarly to the pistons described with respect to FIG. 3 A and FIG. 3B. The intake system may intake clean, filtered air into the engine where combustion occurs. The intake system may manage the air-fuel mixture and optimize air distribution to ensure efficient combustion. In some examples, the intake system may mix the filtered air with fuel before entering the ICE. The exhaust may remove byproducts of combustion, such as exhaust gases, from the ICE 112 to outside of the vehicle. The exhaust may remove combustion gases, reduce emissions, reduce noise, and improve engine performance, for example, by removing exhaust gases from the cylinders to maintain airflow through the ICE, producing more power.

[0066] The depicted ICE 112 may include two cam-tracks 406. The piston groups 408 may provide a linear stroke that is transformed into rotational movement by the interaction between the piston group 408 with the cam-tracks 406. The opposed-piston configuration may open and close exhaust ports before intake ports. For example, the opposed-piston design may involve two pistons moving towards each other in each cylinder, such that a cylinder head may not be needed. The opposed-piston design may also provide compression and power stroke within acompact space, such as the cavity described herein. By reducing the number of components, the opposed-piston setup may improve thermal efficiency and reduce energy losses. Accordingly, the ICE 112 in FIG. 4 for REX applications may combine the efficiency and low emissions of a 4-stroke engine with the simplicity, compacity, and power of a 2-stroke engine (e.g., or a 1 -stroke engine).

[0067] In some examples, the ICE 112 may operate as the 1-stroke engine. In such examples, the ICE 112 may not have emission issues that may be associated with higher quantity stroke ICEs 112. For example, there may be no oil in the mix and pressurized lubricated areas may be far from the combustion chamber of the ICE 112.

[0068] The ICE 112, as the 1-stroke and 2-stroke engine, may charge the HV battery of the vehicle (e.g., when the charge is below a threshold) and provide auxiliary power to increase the vehicle’s driving range. Accordingly, the ICE 112 (e.g., as a 1-Stroke REX) may operate when the EV battery is low rather than constantly consuming fuel. The ICE 112, as the 1-stroke and 2-stroke engine, may be compact, leaving room for the HV battery and motors discussed herein, as well as additional components. In some examples, when the ICE 112 is a 2-stroke engine, the ICE 112 may not have a crankshaft, valves, camshaft, cylinder head, the ICE 112 may be substantially smaller and lighter than a 4-stroke engine. FIG. 4B is schematic view of the ICE 112 of FIG. 4A. The schematic view 450 illustrates the position of a cylinder 454 with respect to pistons 452 (e.g., piston group 408) of the REX.

[0069] FIG. 5 is an example of a power module 250 including the REX of FIG. 1, in accordance with one or more aspects of the present disclosure. The power module 250 may include the HV battery 104, the fuel tank 106, and the REX 110 (including the ICE 112 and / or the generator 114), along with other components, such as an integrated exhaust and muffler, as well as a motor generator and air filter. The power module 250 may include a cover 502 (e.g., lid). The cover 502 may protect the internal components of the power module 250, for example by providing a physical barrier that protects the internal components from external elements (e.g., debris, moisture, contaminants, etc.). The cover 502 may also provide structural integrity of the power module 250. In some examples, the cover 502 may also provide thermal management by reducing heat dissipation through the cover. In some examples, the generator 114 may disposed with the ICE (e.g., of the REX). The cover 502 may include or be lined with materials for thermal management, electromagnetic interference (EMI) shielding, and safe access for maintenance. Accordingly, the cover 502 may facilitate in the vehicle preforming as expected, for example, making the power module 250 operate reliably and safely in a variety of operational environments.

[0070] As illustrated, the cover 502 may protect, for example, the fuel tank 106, an inverter 510, a muffler 506, a generator 114, an air filter 302, and REX ECU 304 or (engine control module (ECM)). Such components may operate and functions based on the respective descriptions described herein, as discussed with respect to FIGs. 3 A, 3B, 3C, and 4.

[0071] The power module 250 may be a single package. By grouping related components or subsystems into a single module, spatial efficiency of the power module 250 is ensured since the power module 250 already includes the components arranged according to the dimensions of the cavity discussed herein. The power module 250 may also be mounted and integrated with other components of the vehicle. By packaging components in a single module, the power module 250, may facilitate space optimization by fitting parts together more compactly and efficiently and in accordance with spatial and operations consideration of other components of the vehicle, as discussed herein.

[0072] The above specification and examples provide a complete description of the structure and use of illustrative embodiments. Although certain embodiments have been described above with a certain degree of particularity, or with reference to one or more individual embodiments, those skilled in the art could make numerous alterations to the disclosed embodiments without departing from the scope of this invention. As such, the various illustrative embodiments of the products, systems, and methods are not intended to be limited to the particular forms disclosed. Rather, they include all modifications and alternatives falling within the scope of the claims, and embodiments other than the one shown may include some or all of the features of the depicted embodiment. For example, elements may be omitted or combined as a unitary structure, and / or connections may be substituted. Further, where appropriate, aspects of any of the examples described above may be combined with aspects of any of the other examples described to form further examples having comparable or different properties and / or functions, and addressing the same or different problems. Similarly, it will be understood that the benefits and advantages described above may relate to one embodiment or may relate to several embodiments.

[0073] The claims are not intended to include, and should not be interpreted to include, means-plus- or step-plus-function limitations, unless such a limitation is explicitly recited in a given claim using the phrase(s) “means for” or “step for,” respectively.

Claims

CLAIMS1. A hybrid vehicle comprising:an electric motor coupled to and configured to drive one or more wheels of the vehicle; a floor pan;a high-voltage battery configured to supply power to the electric motor, the high- voltage battery being positioned beneath the floor pan;a range extender including:an internal combustion engine; anda generator coupled to the internal combustion engine, the generator configured to supply power to charge the high-voltage battery; anda fuel tank configured to store fuel for the internal combustion engine, the fuel tank being positioned beneath the floor pan adjacent the high-voltage battery and having a height that is substantially the same as a height of the high-voltage battery.

2. The hybrid vehicle of claim 1, wherein:the floor pan defines a cavity; andthe range extender is positioned beneath the floor pan such that the internal combustion engine is disposed within the cavity and between a front wheel center of the vehicle and a rear wheel center of the vehicle.

3. A hybrid vehicle comprising:an electric motor coupled to and configured to drive one or more wheels of the vehicle; a floor pan that defines a cavity;a high-voltage battery configured to supply power to the electric motor, the high- voltage battery being positioned beneath the floor pan; anda range extender positioned beneath the floor pan, the range extender including:an internal combustion engine; anda generator coupled to the internal combustion engine, the generator configured to supply power to charge the high-voltage battery;wherein the internal combustion engine is disposed within the cavity and between a front wheel center of the vehicle and a real wheel center of the vehicle.

4. The vehicle of claim 2 or 3, wherein the cavity is positioned forward of a rear wheel of the vehicle.

5. The vehicle of any of claims 2-4, wherein at least a portion of the cavity is positioned beneath a rear seat of the vehicle.

6. The vehicle of any of claims 2-5, wherein the cavity has:a length of at least 500 millimeters (mm); anda height of at least 280 mm.

7. The vehicle of any of claims 2-6, wherein a fuel pump configured to supply fuel to the internal combustion engine is disposed within the cavity.

8. The vehicle of any of claims 2-7, wherein the generator is disposed within the cavity.

9. The vehicle of any of claims 1-8, wherein the internal combustion engine includes: annularly disposed combustion chambers; andfor each of the combustion chambers, opposing pistons reciprocatably disposed therein.

10. The vehicle of any of claims 1 -8, wherein the internal combustion engine is a flat engine or a boxer engine.

11. The vehicle of claim 9 or 10, comprising a supercharger configured to supply compressed air to the internal combustion engine.

12. The vehicle of claim 11, wherein the supercharger is an electric supercharger.

13. The vehicle of claims 1-8, wherein the internal combustion engine is a turbine engine.

14. The vehicle of any of claims 1-13, wherein the generator comprises an electric motor configured to start the internal combustion engine.

15. A method of manufacturing vehicles, the method comprising:coupling a first high-voltage battery to a floor pan of a first vehicle defining a space for the first high-voltage battery;coupling a second high-voltage battery to a floor pan of a second vehicle, wherein: the floor plan of the second vehicle is the same as the floor plan of the first vehicle; andthe second high-voltage battery has a length that is at least 5% less than a length of the first high-voltage battery; andcoupling a fuel tank to the floor pan of the second vehicle such that the fuel tank is at least partially disposed in the space for the first high-voltage battery.

16. The method of claim 15, wherein the fuel tank has a height that is substantially the same as a height of the first high-voltage battery.

17. The method of claim 15 or 16, wherein:the floor pan of the second vehicle defines a cavity; andthe method further comprises:coupling a range extender to the second vehicle, the range extender including an internal combustion engine and a generator coupled to the internal combustion engine, the generator configured to supply power to the second high-voltage battery;wherein the coupling of the range extender to the second vehicle is performed such that the internal combustion engine is disposed within the cavity and between a front wheel center of the second vehicle and a rear wheel center of the second vehicle.

18. The method of claim 17, wherein the cavity has:a length of at least 500 millimeters (mm); anda height of at least 280 mm.

19. The method of claim 17 or 18, wherein a fuel pump configured to supply fuel to the internal combustion engine is disposed within the cavity.

20. The method of any of claims 17-20, wherein the generator is disposed within the cavity.

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